Electric switch



Marl'nl l0, 1942. G. J, MEUER ELECTRIC SWITCH 2 sheesheet 1 Filed NOV. 18, 1940 March 10, 1942. G, 1 MEUER 2,275,789

ELECTRIC SWITCH Filed Nov. 18, 1940 2 Sheets-Sheet 2 NT vQFFICE ELECTRIC SWITCH' George J. Meuer, Milwaukee, Wis., assignor to Cutler-Hammer, Inc., Milwaukee, Wis., a corporation of Delaware Application November 18, 1940, SerialNo. 366,105 8 Claims. (Cl. 209-1772) This invention relates to improvements in elec- This application is a continuation in part of tric switches. The invention relates more parmy application, -Serial No. 233,828, led October ticularly to improvements in toggle operated snap 7, 1938, for improvements in Electric switches, switches of the tool-handle type. nowv Patent No. 2,247,247, dated June 24, 1941.

An Objectis to provide a switch operating lever Referring-first to Figs. 1 to 3 and 6, wherein I having novel means for pivotally supporting and have illustrated a toggle lever snap action switch guiding the same whereby wobbling or lateral of thev tool-handle typehaving an alternating displacement of the lever is substantially precurrent con-trolling capacity of amperes at vented. 250 volts or` 12 amperes at 125 volts,itis to be Other objects and advantages of the invention 10 understood that the switch mechanism embodies will hereinafter appear. certain features described and claimed in my The accompanying drawings illustrate certain prior Patents No. 1,889,259, dated Nov. 29, 1932;

embodiments of the invention which will now No. 1,977,078, dated Oct. 16, 1934; and No. 2,089,-

be described, it being understood that the em- 032, dated Aug. 3, 1937; reference being had to bodiments illustrated are susceptible of modicasaid prior patents for a detailed descriptionfof tion in respect of certain details of construction certain of the switch parts. thereof without departing from the scope of my Here, as in said prior patents, I provide a invention as dened in the appended claims. molded insulating base, designated in general by In the drawings, Figure 1 is a top view (normal the numeral I5, said base having a recess I5 (Fig. size) of a toggle lever operated snap switch of 2) opening to the upper surface thereof. Base the tool-handle type, said switch having novel I5 is provided with a rib whose at surface I7 means for mounting the same in a tool-handle or (Fig. 2) is offset upwardly from the bottom wall the like, and the same having elements applied ofr recess IB. Slidable upon surface Il is a fiat thereto to render the same substantially dustpunched insulating plate I8 Which carries a pair tight. of like contactors arranged on opposite sides of Fig. 2 isa sectional view (double-scale) on the said rib. One of said contactors is shown at I9 as line 2 2 of Fig. 1. comprising a metal strip bent to substantially Fig. 3 is a sectional view, on the line 3-3 of U-shape, whereby the arms thereof are exposed Fig. 1. on the upper and lower surfaces of plate I8. Fig. 4 is a view (normal size), partly in side 30 Said' contactors are rigidly and permanently seelevation and partly in vertical section, illuscured to plate I8 as by means of rivets, one of trating a switch generally similar to the switch which is shown at 2i). A pair of upper and lower of Figs. 1 to 3, but having mounting means of resilient stationary contacts 2| vand 22 is posimodified form applied thereto. tioned on each side of the aforementioned rib Fig. 5 is an end elevation, partly in vertical 35 within recess I6, the respective .contacts being section on the line 5 5 of Fig. 4. secured to ledges oiset downwardly from the Fig. 6 is a fragmentary vertical sectional View upper surface of base I5 as by means of a corof the pivotal supporting and guiding means for responding number of internally threaded eyelet the toggle lever shown in Figs. 1 to 5. members which provide for bottom wiring of the Fig. 7 is a view quite similar to Fig. 3, but illus- 40 switch, in the manner illustrated in Fig. 4, of my trating a modied form of tubular member afaforementioned Patent No. 2,089,032. Two of the fording a wide pivotal support for the lever, Wiring terminal screws are shown herein at 23 in which tubular member also acts to prevent sub- Fig. 3. y

stantial lateral displacement of the lever, the The toggle snap action mechanism for the sheet metal top plate being provided with an switch comprises a wire yoke member 24 pivotalopening of sufficiently large size to accommodate ly supported above base I5 but depending into the ball or knob after attachment of the latter the recess I6; a toggleI operating lever 25 pivotalto the lever, and ly supported above yoke 24; a iiat punched in- Fig. 8 is a fragmentary view, partly in elevasulating plate 26 pvotallySuPDOlted by Sad YOke. tion and partly in vertical section, showing my the lower end of plate 26 projecting into a slot improved tubular member attached to a lever to or opening I8a in plate I8 to provide a lost moaiord a wide pivotal support, and to limit the tion driving connection between said plates. A;

lever to oscillatory movement in a single plane, coiled spring'Z'I is interposed under compression when associated with the externally threaded Y between the lower end of lever 25 and plate 26, a bushing of a one-hole mounting type of switch. portion of which telescopes into the lower end of ing clearance for yoke 24 and the aforementioned n v parts associated therewith. Superimposed upon plate 29 is a sheet metal top plate the peripheral flange portion of which is designated by the numeral 3l in Figs. 2 and 3, said top plate having a centrally located portion Sia of substantially dome-shape. Dome-shaped portion 3la is provided at its upper end with a relatively narrow opening or slot SIb extending in a direction longitudinally of base I5, opening SIb having a width to rather closely accommodate lever 25 comprising a flat sheet metal punching, and the length of opening SIb being such as to provide a rather close oscillating clearance for the arc-shaped portions 25D forming an enlargement of said lever. Opening 3lb thus serves to guide lever 25 for oscillatory movement in a single plane, whereas said portions 25h of the lever insure substantial closure of said opening 3lh under all conditions.

Dome-shaped portion Bia is provided adjacent to the lower end thereof with alined openings 3Ic, 3ld (Fig. 3) into one of which an outwardly bent end of one arm of yoke 2d is freely insertable, the bent end of the other arm of said yoke being insertable into the other opening by temporarily bending the yoke arms toward each other. Portion Sie is provided adjacent to the upper end thereof with alined openings 3Ie, 3If which are respectively vertically alined with openings Si and Sid. Openings Sie, Blf are adapted to receive a pin 32 of circular form in transverse cross section, said pin having a head 32Il engaging the exterior of one side of portion 3la and a hollow shank end 52h which is upset over the exterior' of the other side wall of said portion Sla. Pin 32 freely penetrates the passage of corresponding circular form in transverse cross section provided in a relatively long metal member 33 to provide a relatively wide area of bearing engagement between the latter and said pin. Member 33 is provided at its midlength with a portion 33a of exteriorly polygonal form (preferably square, as best shown in Fig. 2) in transverse cross section. Lever 25 is provided with an opening 25c to accommodate, with a rather close sliding t, the portion 33a, said portion 33a extending beyond each side of lever 25, and the material of said portion being upset against opposite sides of lever 25, as shown at 33h in Figs. 3 and 6, to rigidly and permanently secure said parts in assembled relation.

In practice the pin 32 is free to cscillate or rotate within the aforementioned openings SIE, 3|f (Fig. 6), but pivotal movement of lever 25 is afforded primarily by the bearing engagement of tubular member 33 with pin 32. By reason of the rigid connection between lever 25 and member 33 and the relatively wide area of bearing engagement of the latter with pin 32 lateral tilting or wobbling of said lever is prevented. Also as aforedescribed the walls of opening @Ib in dome-shaped portion Sla cooperate with lever 25 to limitV the same to oscillatory movement in a single plane. This insures against accidental lateral displacement of the lower end of lever 25 from the cup or abutment 28 at the upper end of spring 21.

Many portable tools (such as grinders, polishers or drills) are used under conditions involving the presence of metal dust, stone dust, or other particles in the surrounding air; and if such dust particles have access to the switch chamber they, of course, tend to ruin the switch mechanism and to greatly reduce the useful life of the latter. It is accordingly a primary object of my invention to render the switch chamber substantially dust-tight, and this object is attained in the device of Figs. l to 3 by providing a relatively thin walled, dome-shaped insulating member 34 molded from a resilient, rubber-like material. Member 54`and the aforementioned plate 3l) may be and preferably are composed of identical resilient, rubber-like material, a preferred form of such material being made and sold commercially under the trade-name of Neoprene Such material is extremely live and resilient (or elastic) and is further characterized by its resistance to deterioration under the influence of, or

in the presence of, oil or grease.

As best shown in Figs.,2 and 3 member 34 is provided with a slot or opening 34ZL which it is to be understood is relatively narrower than the thickness of lever 25 and relatively shorter-than the width of the enlarged portion (comprising arcuate portions 25h) of said lever. Therefore the walls of said opening 34a will be biased by the resiilency of the rubber-like material into close engagement with the sides and edges of lever 25 in all positions of the latter, the resiliency or elasticity of member 34 being such as to permit bodily deformation or distortion thereof as an incident to oscillatory movement of said lever while maintaining said close connection of member 34 with the latter.

Also as best shown in Figs. 2 and 3 member( 34 is provided at its lower end with a flange portion 34b which overlies the aforementioned top plate 3|, said fla-nge portion 34h being provided with a downwardly extending edge portion or peripheral rib 34C which surrounds the peripheral edge of top plate 3l and engages the aforementioned metal plate 25. superimposed upon flange portion 34h is a metal plate 35 having a relatively large centrally located opening 35a to accommodate said dome-shaped member 34. Plate 35 has associated therewith a pair of nuts here shown as substantially cylindrical ele-r ments having threaded passages 36a extending therethrough. Elements 35 i are provided at their lower ends with reduced portions 36b adapted to extend downwardly through correspondingly shaped openings in plate 55, the material of said reduced portions being upset over the lower surface of plate 35, as shown at 36C, to rigidly and permanently secure said nuts to said plate. Elements 36 are provided with further reduced portions 351 projecting downwardly through corresponding openings in flange portion 34h and metal top plate 3i to afford a proper degree of engagement of elements 35 with the threaded Shanks of a pair of bolts 3l extending upwardly from the bottom surface of base I5.

The flat upper ends of elements 3G are adapted to abut the inner surface of the wall of a cavity provided in a tool-handle or the like (not shown), said wall having openings formed therein to provide clearance for the Shanks of mounting screws or bolts which take into the 35?. Said cavity wall will of course be provided with a suitable opening to afford oscillating clearance for the upper end portion of lever 25. As shown in dotted lines in Fig. 2 lever 2'5 is provided at its upper end with a reduced portion Zed whichris adaptedfor a drive t within a recess provided in a spherical knob member 25e. As will be understood, knob 25e is applied to lever 25 after upward insertion of the latter through the aforementioned opening 35h in portion 39a of the top plate. The walls of opening 34a in the dust-proong cap 34 are suiilciently elastic to permit downward passage of said cap over knob 25e and the intermediate portion of said lever.

In the modiiication shown in Figs. 4 and 5 most of the switch parts are identical with those aforedescribed and have been given corresponding numerals of reference. Instead of the plate 35 and nuts 36 aforedescribed, the switch'is provided with a plate 38, preferably of die cast aluminum, the opposite ends of plate 33 extending beyond the respective ends oi base l5 and having openings 38a, 38b to accommodate the shanks of securing screws (not shown) which take into suitable tapped openings in the wall of a portable tool housing or handle. Plate 33 is provided with a central opening 33C to accommodate the dome-shaped dust-proofing cap 34 and the operating lever 39 extending upwardly through the latter, lever 39 having a spherical knob 39a attached thereto with a drive t in the manner aforedescribed.

Formed integrally with plate 3S and extending upwardly at substantially right angles thereto adjacent the opposite longitudinally spaced sides of opening SSC are a pair of transverse ribs 38d and 38e, said lugs having segmental notches or concavities 38f, 38g formed in the upper edges thereof and alined with each other. Notches 38f, 38g provide ample clearance to enable thumb operation of lever 39 in either direction, whereas the high portions of ribs 38d, 38E serve to prevent accidental operation of lever 39 or injury thereto in the event of rough or careless usage of the tool to which the switch may be attached. The :l

switch base l5 and its associated parts are attached to plate 33 as by means of a pair of relatively long bolts 40 which penetrate tapped openings provided in the aforementioned ribs 38d, 38e, the upper ends of said bolts being upset, as shown at 40a, to permanently secure the parts in assembled relation.

In the form of the invention illustrated in Fig. 7 certain of the parts may be identical with the corresponding aioredescribed parts, and the same have been given like numerals of reference. In Fig. '7, however, the tubular member 4l is made relatively longer than the member 33 of Fig. 3, thus providing a still wider pivotal bearing or support for lever with respect `to pin 32. Member I is provided at its mid-length with a portion la of square form in transverse cross section to t closely within a correspondingly shaped opening (not shown in Fig. 7) in lever 25; and the material ci portion lia being upset against opposite sides oi lever 253, as shown at Mb and iii to rigidly and permanently secure lever 25 and member di in assembled relation.

The metal top plate l2 is provided with a centrally located hollow projection 42a of substantially dome-shape, and the ends or" member di are adapted to i'lt rather closely (but rotatably) between the opposed inner surfaces of the wall of projection 42a, to thereby prevent substantial lateral displacement of member 4l and lever 25 with respect to the top plate t2. Moreover, pro'- jection lita is provided in its substantially flat upper end @2b with a `substantially circular opening 42C, `the diameter V'of which opening is at least slightly greater than the y'diameter of the ball or knob 25e, to permit upward insertion of the latter through said opening after said knob has been attached to lever 25. This arrangement facilitates or kexpedites the assembly oil the switch parts.

The relatively thin-walled, dome-shaped, rubber-like member 133 is substantially like the member tl aforedescribed and perfo-rms the function of rendering the switch of Fig. 7 substantially dust-tight. Member i3 is provided with a slot or opening @3a which is relatively narrower than the thickness of lever 25 and relatively shorter than the width of the enlarged portion of thev lever which` extends upwardly therethrough. Member d3 is clamped in position by the metal plate or ring .t5v which carries the nuts (one oi which is shown at 3d.) forcooperation with the securing bolts (not shown in Fig. 7 as described in connection with the switch of Figs. -l to 3 and 6. The headed pin 32 has its shank extending through member li and through Valined `openings in the opposed sides of the projection 42a cf the top plate, the shank end of said pin being upset at 321 (as aforedescribed) to reta-in said parts in assembled relation.

The lever it in Fig. 8 has attached thereto, in the man-ner described -i-n connection with the other switch levers, a tubular member 45 whose opposite ends are adapted to rotatably abut the diametrically opposite curved inner surface portions Mia and b of an externally threaded tubular bushing l5 which is attached in any usual or well known manner to the hollow bulge or projection l? of a punched and stamped sheet metal top plate for a switch. A pin d'8 penel trates member t5 and alined openings in the side walls of bushing-4G, the `head 38a and upset shank end 481 of said pin are located in countersinks or recesses in the exteriorof bushing ll toavoid interference thereoiwith the clamping nut or nuts (not shown) which are usually employed in a switch of theorie-hole mounting type. K

As will be apparent, the tubular member `$5 insures a maximum width of .pivotal bearing surface for lever dit with respect to pin d8, whereas the length of member i5 is so related to the inner surface of bushing i6 as to preventsubstantial lateral displacement oi the same and oi lever i4 with reference to the bushing. In this simple manner the lever dit is substantially restricted to oscillatory mvement `in a single plane. Lever M preferably has a ball or knob 25e attached to the upper end thereof vin the manner aioredescribed.

I claim:

1. In an electric switch of the tool-handle type, rin combination, a punched and stamped sheet metal top plate having a flat peripheral flange and a substantially centrally located domeshaped portion extending upwardly from said flange, said dome-shaped portion having a relatively narrow opening formed in the upper end thereof, a at punched sheet metal lever having an intermediate portion located within said opening and oscillatable with respect thereto, said lever having an opening of polygonal contour formed therein, a tubular metal member having an intermediate portion of a contour closely corresponding to said'opening and slidably insertable thereinto, the'material of lsaid intermedia-te portion of the tubular member being upset against opposite sides of said lever to retain said parts in assembled relation, said dome-shaped portion having alined openings formed in opposite side walls thereof, and a pin freely penetrating said openings and said tubular member to provide a pivotal support for the latter.

2. In an electric snap switch of the tool-handle type, in combination, a hollow metal member having a top wall and peripheral side walls, said top wall having a relatively narrow elongated opening formed therein, a flat punched sheet metal operating lever having an intermediate enlarged portion positioned within said opening and guided by the side walls of the latter for oscillatory movement in a single plane, said enlarged portion being adapted to substantially close said opening in all positions of said lever, the lower portion of said lever having a substantially square opening formed therein, a relatively long metal member having a straight passage of substantially circular form in transverse cross section extending therethrough, said metal member being provided at its mid-length with a portion of externally square form in transverse cross section to ilt rather closely within said lever opening, said portion of externally square form extending beyond each side of said lever and the material thereof being upset against said sides respectively to retain said parts in assembled relation,

said hollow metal member having alined openings formed in opposite side walls thereof, and a headed pin the cylindrical shank of which is freely insertable through said alined openings and through said passage in` the metal member y to provide a relatively wide bearing for the latter, the shank of said pin having a hollow end which is upset over the exterior of said hollow metal member to permanently secure said pin in assembled relation- 3. In an electric snap switch of the tool-handle type, in combination, a hollow metal member having a top wall and peripheral side walls, said top wall having a relatively narrow elongated opening formed therein, a fiat punched sheet metal operating lever having an intermediate enlarged portion positioned within said opening and guided by the side walls of the latter for oscillatory movement in a single plane, said enlarged portion being adapted to substantially close said opening in all positions of said lever, the lower portion of said lever having a substantially square opening formed therein, a relatively long metal member having a straight passage of substantially circular form in transversev cross section extending therethrough, said metal member being provided at its mid-length with a portion of externally square form in transverse cross section to t rather closely within said lever opening, said portion of externally square form extending beyond each side of said lever and the -material thereof being upset against said sides lrespectively to retain said parts in assembled relation, said hollow metal member having alined `openings formed in opposite side walls thereof, a headed pin the cylindrical shank of which is freely insertable through said alined openings and through said passage in the metal member to provide a relatively wide bearing for the latter, the shank of said pin having a hollow end which is upset over the exterior of said hollow metal member to permanently secure said pin in assembled relation, said lever having an upper end portion of reduced width, and a substantially spherical knob having a recess, said reduced upper end of said lever being insertable with a drive t into said recess after positioning of said lever within said opening.

4. In an electric switch, in combination, a punched and stamped sheet metal top plate having a relatively narrow opening formed therein, a flat metal lever having an intermediate portion located within said opening and oscillatable with respect thereto, said lever having an opening of polygonal contour formed therein, a one-piece tubular metal member having an intermediate portion of a contour closely corresponding to said opening and slidably insertable thereinto, the material of said intermediate porti-on of the tubular member being upset against opposite sides of said lever to retain said parts in assembled relation, said top plate having alined openings formed therein, and a pin freely penetrating said openings and said tubular member to provide a pivotal support for the lever.

5. In an electric snap switch, in combination, a hollow met-al member having a top wall and peripheral side walls, said top wall having a relatively narrow elongated opening formed therein, a ilat metal operating lever having an intermediate enlarged portion positioned within said opening and guided by the side walls of the latter for oscillatory movement in a single plane, said enlarged portion being adapted to substantially close said opening in all positions of said lever, the lower portion of said lever having an opening of polygonal contour formed therein, a relatively long metal member having a straight passage of substantially circular form in transverse cross section extending therethrough, said last mentioned member being provided at its mid-length with a portion of polygonal contour in transverse cross section to lit rather closely within said lever opening, said last mentioned portion extending beyond each side of said lever and the material thereof being upset against said sides respectively to retain said parts in assembled relation, said hollow metal member having alined openings formed in opposite side walls thereof, and a headed pin the cylindrical shank of which is freely insertable through said alined openings and through said passage in said relatively long metal member to provide a relatively wide bearing for the latter, the shank of said pin having a hollow end which is upset over the exterior of said hollow metal member to permanently secure said pin in assembled relation.

6. In an electric snap switch, in combination, a hollow metal member having a top wall and peripheral side walls, said top wall having a relatively narrow elongated opening formed therein, a flat sheet metal operating lever having an intermediate enlarged portion positioned within said opening and guided by the side walls of the latter for oscillatory movement in a single plane, said enlarged portion being adapted to substantially close said opening in all positions of said lever, the lower portion of said lever having an opening of polygonal contour formed therein, a relatively long metal member having a straight passage of substantially circular form in transverse cross section extending therethrough, said last mentioned member being provided at its mid-length with a portion of polygonal contour in transverse cross section to t rather closely within said lever opening, said last mentioned portion extending beyond each side of said lever and the material thereof being upset against said sides respectively to retain said parts in assembled relation, said hollow 4metal member having alined openings formed in opposite side walls thereof, a headed pin the cylindrical shank of which is freely insertable through said alined openings and through said passage in said relatively long metal member to provide a relatively wide bearing for the latter, the shank of said pin having a hollow end which is upset over the exterior of said hollow metal member to permanently secure said pin in assembled relation, said lever having an upper end portion of reduced width, and a substantially spherical knob having Ia recess, said reduced upper end of said lever being insertable with a drive iit into said recess after positioning of said lever within said openng.

7. In an electric switch, in combination, a metal support member having opposed substantially vertical side walls, a i'lat metal lever to be positioned between said side walls in equally spaced relationship thereto, said lever having an opening of polygonal contour formed therein, a one-piece tubular metal member having an intermediate portion of a. contour closely corresponding to said opening and slidably insertable thereinto, the material of said intermediate portion of the tubular member being upset against' opposite sides of said lever to retain said parts in assembled relation, said sidewalls of said support member havin-g alined openings formed therein, and a pin freely penetrating said openings and said tubular member to provide a pivotal support for the lever.

8. In an electric switch, in combination, a metal support member having opposed substantially vertical side walls, la flat metal lever to be positioned between said side walls in equally spaced relationship thereto, said lever having an opening of polygonal contour formed therein, a one-piece tubular metal member having an intermediate portion of Ia contour closely corresponding to said opening and slidably insertable thereinto, the material of said intermediate portion of the tubular member being upset against opposite sides of said lever to retain said parts in assembled relation, said side Walls of said support member having alined openings formed therein, and a pin freely penetrating said openings and said tubular member to provide a pivotal support for the lever, said tubular member being of a lengthonly slightly less than the distance between said side walls, whereby said lever is substantially limited to oscillatory movement in a single plane. l

GEORGE J. MEUER. 

